U.S. patent application number 13/159838 was filed with the patent office on 2011-12-15 for redispersible polymer powder compositions prepared from styrene butadiene-based latex for dry mix formulations.
Invention is credited to Jurgen Dombrowski, Hartmu Kuhn, Etienne Lazarus, Gerold A. Lohmuller, Margarita Perello.
Application Number | 20110306705 13/159838 |
Document ID | / |
Family ID | 44246600 |
Filed Date | 2011-12-15 |
United States Patent
Application |
20110306705 |
Kind Code |
A1 |
Dombrowski; Jurgen ; et
al. |
December 15, 2011 |
REDISPERSIBLE POLYMER POWDER COMPOSITIONS PREPARED FROM STYRENE
BUTADIENE-BASED LATEX FOR DRY MIX FORMULATIONS
Abstract
Redispersible polymer powder compositions which include a
polyglycol in admixture with a redispersible polymer powder (RDP),
which powder includes a codried mixture of a carboxylated, water
insoluble film-forming styrene butadiene polymer and a colloidal
stabilizer, results in cement compositions having unexpectedly
superior overall bonding strength and adhesion after water
immersion. Use of the polyglycol provides good workability or ease
of troweling during application. In addition, the RDP composition,
which includes the RDP and the polyglycol, provides the
cement-based composition with excellent abrasion resistance,
surface appearance, and color. Also, the RDP composition provides
for at least a 30% reduction, for example a 50% or more reduction
in the amount of retarder or retardant employed in the dry mix
formulation for cement compositions, such as self leveling flooring
compounds or compositions, and cement-based tile adhesives.
Inventors: |
Dombrowski; Jurgen; (Halle,
DE) ; Kuhn; Hartmu; (Halle, DE) ; Perello;
Margarita; (Dubendorf, CH) ; Lohmuller; Gerold
A.; (Baden-Baden, DE) ; Lazarus; Etienne;
(Marienthal, FR) |
Family ID: |
44246600 |
Appl. No.: |
13/159838 |
Filed: |
June 14, 2011 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
61397635 |
Jun 15, 2010 |
|
|
|
Current U.S.
Class: |
524/5 ;
524/503 |
Current CPC
Class: |
C08J 2313/02 20130101;
C08L 71/02 20130101; C08J 2329/04 20130101; C08L 13/00 20130101;
C08L 2201/56 20130101; C08J 2325/10 20130101; C04B 40/0042
20130101; C08K 3/36 20130101; C08J 2371/02 20130101; C04B 2103/0057
20130101; C08J 3/12 20130101; C04B 28/02 20130101; C08L 29/04
20130101; C04B 28/02 20130101; C04B 24/2676 20130101; C04B 24/32
20130101; C04B 40/0608 20130101; C04B 40/0042 20130101; C04B
24/2676 20130101; C04B 24/32 20130101; C08L 13/00 20130101; C08L
2666/22 20130101; C08L 71/02 20130101; C08L 9/06 20130101; C08L
13/00 20130101; C08L 25/10 20130101 |
Class at
Publication: |
524/5 ;
524/503 |
International
Class: |
C04B 24/26 20060101
C04B024/26; C08L 29/04 20060101 C08L029/04 |
Claims
1. A water redispersible polymer powder composition comprising an
admixture of: a) a water redispersible polymer powder (RDP), said
water redispersible polymer powder (RDP) comprising a co-dried
admixture of a water insoluble film-forming polymer and a colloidal
stabilizer, said film forming polymer comprising a carboxylated
styrene-butadiene copolymer or the copolymerization product of
styrene, butadiene, a carboxylic acid and one or more other monomer
and b) a polyglycol, the amount of polyglycol being from 0.001% by
weight to 10% by weight, based upon the weight of the water
redispersible polymer powder (RDP), wherein the polyglycol may be
admixed before or after co-drying of the admixture of the water
insoluble film forming polymer and the colloidal stabilizer.
2. A water redispersible polymer powder composition as claimed in
claim 1 wherein the amount of polyglycol is from 0.01% by weight to
5% by weight, based upon the weight of the water redispersible
polymer powder (RDP).
3. A water redispersible polymer powder composition as claimed in
claim 1 wherein the polyglycol is a polypropylene glycol.
4. A water redispersible polymer powder composition as claimed in
claim 1 wherein the polyglycol has a number average molecular
weight of from 250 to 10,000 and the water insoluble film-forming
polymer is a copolymer comprising the monomers styrene, butadiene,
and an unsaturated dicarboxylic acid.
5. A water redispersible polymer powder composition as claimed in
claim 1 wherein the polyglycol is in the form of a dry preblend
with an amorphous silica powder, the colloidal stabilizer comprises
a polyvinyl alcohol, and the water insoluble film-forming polymer
has an amount of carboxylation of from 0.1% by weight to 15% by
weight of at least one ethylenically unsaturated dicarboxylic-acid,
salts thereof, or mixtures thereof, based upon the weight of the
water insoluble film forming polymer.
6. A method for producing a water redispersible polymer powder
composition comprising: a) drying an aqueous mixture of a water
insoluble film-forming polymer and a colloidal stabilizer to obtain
a water redispersible polymer powder (RDP), wherein the film
forming polymer comprises a carboxylated styrene-butadiene
copolymer or a styrene butadiene copolymerized with another
monomer, and b) admixing the water redispersible polymer powder
(RDP) with a polyglycol, the amount of polyglycol being from 0.001%
by weight to 10% by weight, based upon the weight of the water
redispersible polymer powder (RDP), or c) drying an aqueous mixture
of said water insoluble film-forming polymer, said colloidal
stabilizer, and said polyglycol to obtain a water redispersible
polymer powder composition, the amount of polyglycol being from
0.001% by weight to 10% by weight, based upon the weight of the
water redispersible polymer powder composition.
7. A method for producing a water redispersible polymer powder
composition as claimed in claim 6 wherein the polyglycol is
preblended with an amorphous silica powder to obtain a dryblend,
and the dryblend is admixed with the redispersible polymer powder
(RDP) to obtain a water redispersible polymer powder composition,
the colloidal stabilizer comprises a polyvinyl alcohol, and the
water insoluble film-forming polymer has an amount of carboxylation
of from 0.1% by weight to 15% by weight of at least one
ethylenically unsaturated dicarboxylic, and the polyglycol is a
polypropylene glycol.
8. A method for making a cement composition comprising admixing
cement ingredients with a water redispersible polymer powder
composition as claimed in any one of claims 1 to 5.
9. A dry mix formulation comprising cement ingredients and a water
redispersible polymer powder composition as claimed in any one of
claims 1 to 5 in an amount of at least 0.1% by weight, based upon
the weight of the dry mix formulation.
10. A dry mix formulation as claimed in claim 9 where the cement
ingredients are for making a self leveling flooring composition and
the dry mix contains a retardant in an amount of less than 0.07% by
weight, based upon the weight of the dry mix formulation.
Description
[0001] This application claims the benefit of priority under 35
U.S.C. .sctn.119(e) of U.S. Provisional Patent Application No.
61/397,635 filed on Jun. 15, 2010.
FIELD OF THE INVENTION
[0002] The present invention relates to redispersible polymer
powder compositions which are prepared from carboxylated styrene
butadiene copolymer latex and a polyglycol for dry mix formulations
for use in cement compositions.
BACKGROUND OF THE INVENTION
[0003] In construction applications, mortars may be prepared with
cement, sand, and organic polymer. To reduce shipping costs, the
polymer can be shipped and added in dry form as a redispersible
polymer powder. Redispersible polymer powders improve the adhesion
and flexibility of cement based tile adhesives. The powdered form
of the polymer is generally produced by spray drying a liquid
polymer composition to obtain a free flowing powder. To perform its
function in the application formulation to which it is added, such
as cementicious systems, it is desired that in the application
formulation the polymer powder is easily redispersible. Also, in
preparing a redispersible polymer powder (RDP) from a latex or
polymer dispersion by spray drying, a low viscosity polymer
dispersion is desired to enable the use of higher solids content
compositions for easier spray drying and lower pressure equipment
for more efficient production of RDPs without loss of
redispersibility.
[0004] The properties of adhesion, wear resistance, scratch
resistance and bend resistance of hydraulically setting
compositions are generally improved by adding dispersion powders.
Polyvinyl acetate dispersion powders as an additive in flowable
compositions are generally in dry mortar from when they are
delivered to the building site, where they are simply mixed with
water and spread on the floor. The materials flow out to give a
smooth surface which serves directly as the wear layer or serves as
substrate for further coatings. However, this usage exhibits
problems, particularly when relatively thick layers are applied,
such as the formation of uneven areas, such as craters or pinholes,
which form on the surface. The surface does not become as smooth as
the purchaser desires, and requires further work. To avoid uneven
areas of this type, additives, such as fully hydrolyzed copolymers
made from 1-alkylvinyl esters and from vinyl esters have been
employed to eliminate these problems.
[0005] U.S. Pat. No. 6,632,861 to Weitzel et al discloses that the
use of powders based on protective-colloid-stabilized
vinylaromatic-1,3-diene polymers enables the use of expensive,
difficult to prepare, fully hydrolyzed copolymers made from
1-alkylvinyl esters and from vinyl esters to be dispensed with,
while retaining equivalent surface qualities and at the same time
obtaining good wear resistance, scratch resistance and adhesion.
The Weitzel et al water-redispersible,
protective-colloid-stabilized dispersion powder compositions for
use in self-leveling screeds or trowel-applied flooring
compositions, include: a) a base polymer selected from the group
consisting of the vinylaromatic-1,3-diene polymers, b) from 2 to
25% by weight, based on the base polymer, of one or more protective
colloids, c) from 3 to 30% by weight, based on the total weight of
polymeric constituents, of fine antiblocking agent, and d) from 0.1
to 10% by weight, based on the base polymer, of other
additives.
[0006] It has been found that the use of carboxylated
styrene-butadiene redispersible powders as an additive in
self-leveling flooring compounds or compositions generally improves
the abrasion resistance, surface appearance, and color compared to
systems modified with powders based in other chemistries like
vinylacetate/ethylene copolymers. However, improvement in overall
bonding strength without adversely affecting rheology in a
cement-based formulation such as a self-leveling flooring
composition, and a cement based tile adhesive formulation, and
without adversely affecting redispersibility of the carboxylated
styrene butadiene redispersible polymer powder would be highly
desirable.
[0007] Mortars formulated with the carboxylated styrene butadiene
redispersible polymer powder compositions of the present invention
exhibit an unexpectedly superior increase in bonding strength after
water immersion without adversely affecting rheology of the
cementicious mortar or redispersibility of the polymer powder
relative to vinylacetate/ethylene copolymer RDPs and other SB RDPs,
which is advantageous for workability or ease of troweling during
application. Accordingly, the present invention solves the problems
of inadequate abrasion resistance, surface appearance, control of
cement setting and off-colors while achieving unexpectedly superior
overall bonding strength for cement compositions prepared from dry
mix formulations.
SUMMARY OF THE INVENTION
[0008] The present invention provides a redispersible polymer
powder (RDP) composition comprised of an admixture of a
redispersible polymer powder (RDP) and a polyglycol for dry mix
formulations. Addition of the polyglycol to the RDP rather than to
an aqueous mixture prior to formation of the RDP by spray drying
avoids any problems for redispersibility of the RDP. The RDP
includes at least one water insoluble polymer prepared from at
least one water insoluble, carboxylated styrene butadiene (SB)
copolymer latex and a colloidal stabilizer, e.g. polyvinyl alcohol
(PVOH). The water redispersible polymer powder composition of the
present invention imparts an unexpectedly superior increase in
overall bonding strength and adhesion after water immersion to
cement-based compositions without adversely affecting workability
or ease of troweling during application. In addition, the RDP
composition provides the cement-based composition with excellent
abrasion resistance, surface appearance, and color, and enables at
least a 30% reduction, for example a 50% or more reduction in the
amount of retarder employed in the dry mix formulation for cement
compositions, such as self leveling flooring compounds or
compositions, and cement-based tile adhesives.
[0009] The RDP comprises a co-dried admixture of a water insoluble
film-forming polymer and one or more colloidal stabilizer,
preferably a polyvinyl alcohol (PVOH), where the film forming
polymer comprises a styrene-butadiene copolymer or the
copolymerization product of styrene and butadiene with one or more
other monomer. The film-forming polymer may have an amount of
carboxylation of from 0.1% by weight to 15% by weight, preferably
from 0.5% by weight to 10% by weight, more preferably from 1% by
weight to 5% by weight, of at least one ethylenically unsaturated
monocarboxylic acid and/or dicarboxylic acid, salts thereof, or
mixtures thereof, preferably itaconic acid and/or maleic acid,
and/or fumaric acid, based upon the total comonomer weight, or the
weight of the water insoluble film forming polymer, such as a
styrene butadiene copolymer with itaconic acid. The amount of
polyglycol admixed with the RDP to form the RDP composition may be
from 0.001% by weight to 10% by weight, preferably from 0.01% by
weight to 5% by weight, more preferably from 0.1% by weight to 3%
by weight, based upon the weight of the water redispersible polymer
powder (RDP), or the weight of the redispersible polymer powder
composition. The polyglycol, such as a polypropylene glycol, may
have a number average molecular weight of from 250 to 10,000,
preferably from 1500 to 6,000, and may be in the form of a dry
preblend or powder with a flow agent, carrier or adsorbent such as
an amorphous silica powder.
[0010] In an aspect of the present invention, the redispersible
polymer powder composition may be produced by drying an aqueous
mixture of the water insoluble film-forming polymer and the
colloidal stabilizer to obtain the water redispersible polymer
powder (RDP). An aqueous dispersion of the water insoluble
film-forming polymer may be provided by polymerization, and the
colloidal stabilizer may be admixed with the aqueous dispersion
after polymerization, and then the aqueous dispersion may be spray
dried to obtain the water redispersible polymer powder. The water
redispersible polymer powder (RDP) may then be admixed with a
polyglycol, to obtain a redispersible polymer powder composition of
the present invention. In embodiments of the invention, the
polyglycol may be preblended with a flow agent, carrier or
adsorbent such as amorphous silica powder to obtain a dryblend, and
the dryblend may then be admixed with the redispersible polymer
powder (RDP) to obtain a water redispersible polymer powder
composition of the present invention. Use of the polyglycol with
the RDP provides an unexpectedly superior increase in overall
bonding strength and adhesion in cement-based compositions without
adversely affecting workability or ease of troweling during
application, provides excellent abrasion resistance, surface
appearance, and color, and enables a reduction in the amount of
retarder employed in the dry mix formulation for cement
compositions.
[0011] In another aspect of the present invention, a cement
composition such as a cement based tile adhesive, or a self
leveling flooring compound or composition, may be produced by
admixing cement ingredients with the water redispersible polymer
powder composition made from a SB copolymer RDP and a polyglycol to
obtain a cement composition, such as a mortar. The cement
compositions exhibit an unexpectedly superior overall bonding
strength and adhesion, and workability or ease of troweling during
application, while providing excellent abrasion resistance, surface
appearance, and color in the end product.
BRIEF DESCRIPTION OF THE DRAWINGS
[0012] The present invention is further illustrated by the
accompanying drawings wherein:
[0013] The sole FIGURE is a graph showing the effect of polyglycol
on the consistency of cement formulated with a styrene butadiene
redispersible polymer powder (RDP) and a vinylacetate/ethylene
(VAE) redispersible polymer powder (RDP) measured with a Brookfield
Rotating T-Spindel-Helipath.
DETAILED DESCRIPTION OF THE INVENTION
[0014] Unless otherwise indicated, all temperature and pressure
units are room temperature and standard pressure (STP). All ranges
recited are inclusive and combinable.
[0015] All phrases comprising parentheses denote either or both of
the included parenthetical matter and its absence. For example, the
phrase "(meth)acrylate" includes, in the alternative, acrylate and
methacrylate.
[0016] As used herein, the term "(meth)acrylate" means acrylate,
methacrylate, and mixtures thereof and the term "(meth)acrylic"
used herein means acrylic, methacrylic, and mixtures thereof.
[0017] As used herein, unless otherwise indicated, the phrase
"molecular weight" refers to the number average molecular weight as
measured in conventional manner.
[0018] As used herein, the term "polymer" refers, in the
alternative, to a polymer made from one or more different monomer,
such as a copolymer, a terpolymer, a tetrapolymer, a pentapolymer
etc., and may be any of a random, block, graft, sequential or
gradient polymer.
[0019] As used herein, unless otherwise indicated, the measured
glass transition temperature (T.sub.g) is used. As used herein the
term "calculated T.sub.g" refers to the T.sub.g of a polymer
calculated by using the Fox equation (T. G. Fox, Bull. Am. Physics
Soc., Volume 1, Issue No. 3, page 123 (1956)). As used herein the
term "measured T.sub.g" means a T.sub.g that is measured using
differential scanning calorimetry or DSC (rate of heating
10.degree. C. per minute, T.sub.g taken at the midpoint of the
inflection.)
[0020] The present inventors have found that redispersible polymer
powders (RDPs), including a polyglycol, such as, for example,
polypropylene glycol, in admixture with a redispersible polymer
powder, which powder includes a carboxylated, water insoluble
film-forming styrene butadiene polymer having, for example, at
least one ethylenically unsaturated dicarboxylic acid monomer which
provides the carboxylation, and a colloidal stabilizer such as, for
example, PVOH in the redispersible polymer powder, results in
cement compositions having unexpectedly superior overall bonding
strength and adhesion after water immersion to cement-based
compositions, without adversely affecting rheology. It provides
good workability or ease of troweling during application. In
addition, the RDP composition, which includes the RDP and the
polyglycol, provides the cement-based composition with excellent
abrasion resistance, surface appearance, and color. It has also
been found that the RDP composition enables at least a 30%
reduction, for example a 50% or more reduction in the amount of
retarder or retardant employed in the dry mix formulation for
cement compositions, such as self leveling flooring compounds or
compositions, and cement-based tile adhesives. For example,
characterization via bond strength or adhesion after water
immersion, shows that mortars formulated with the redispersible
polymer powder compositions of the present invention exhibit
unexpectedly superior overall bonding and adhesion after water
submersion relative to mortars formulated with
vinylacetate/ethylene copolymer (VAE) or styrene butadiene
redispersible polymer powders without addition of the polyglycol.
Similarly, the final surface testing characteristics of phase
separation, coloration, and pin holes of mortars shows improvement,
plus significant improvement of abrasion resistance is achieved for
polyglycol addition to SB RDPs compared to VAE RDPs which do not
have polyglycol added. Compressive strength and flexural strength
are also greatly improved when the retardant, e.g. trisodiumcitrate
(TrNaCitrate) is reduced. Accordingly, the combination of the
carboxylated styrene butadiene RDP and the polyglycol enables good
redispersibility, ease of production, higher productivity, and
improved end-use performance.
[0021] The polymers which may be employed in the present invention
are water insoluble film-forming polymers which are carboxylated.
Preferred water insoluble film-forming polymers are a
styrene-butadiene copolymer or a styrene and butadiene
copolymerized with other monomers with a low degree of
carboxylation.
[0022] The water insoluble film-forming copolymers can be prepared
by aqueous emulsion or suspension polymerization, preferably
emulsion polymerization, in conventional manner, employing
conventional polymerization temperatures, e.g. from 40.degree. C.
to 120.degree. C., preferably, 70.degree. C. or more, or,
preferably, up to 105.degree. C., and pressures, e.g. with diene
comonomer pressures being 150 psi or below, preferably, 100 psi or
below. The polymerization may be initiated using conventional
amounts of one or more conventional water-soluble such as sodium
persulphate, or oil (monomer) soluble initiator, such as t-butyl
peroxide and cumene hydroperoxide, or a redox initiator
combination, using a reducing agent such as sulfites and
bisulfites. To control the molecular weight, conventional regulator
substances or chain transfer agents, such as mercaptans, alkanols,
and dimeric alpha methylstyrene can be used during the
polymerization in conventional manner in conventional amounts of
from 0.01 to 5.0% by weight, or, preferably, up to 3% by weight,
based on the monomers to be polymerized. The polymerization process
preferably takes place in known manner in the presence of
conventional amounts of one or more conventional emulsifier and/or
protective colloid, such as, for example, water soluble copolymers
having a number average molecular weight of 2000 or more. Suitable
emulsifiers include anionic, cationic and nonionic emulsifiers, for
example anionic surfactants such as, for example, 8 to 18 carbon
alkyl or alkyl aryl ether sulfates, and their salts, and nonionic
surfactants, such as, for example, alkyl or alkyl aryl polyglycol
ethers. Suitable protective colloids, instead of or in addition to
one or more surfactants, may include, for example, polyvinyl
alcohols; polysaccharides in water-soluble form, e.g. starches and
cellulosics; proteins such as, for example, casein or soy protein;
lignin sulfonates; and synthetic copolymers such as, for example,
poly(meth)acrylic acid, and copolymers of (meth)acrylates with
carboxyl-functional comonomer units.
[0023] One or more basic compound may be added before, during or
after polymerization in an amount of 0.4 moles or more, preferably
from 0.5 to 2 moles, more preferably 0.6 to 1.8 moles of carboxylic
groups in the copolymer. Alternatively, the basic compound can be
added in such an amount to adjust the pH of the aqueous copolymer
product to 8.0 or more, or 9.5 or more, or, preferably at least
10.5, and preferably up to 12.5. The basic compound may be an
inorganic basic compound, preferably a strong inorganic basic
compound, such as an alkali metal hydroxide or an alkaline earth
metal hydroxide, such as sodium hydroxide or potassium
hydroxide.
[0024] The copolymers comprise the copolymerization product of from
20 to 79.9%, preferably, 30% or more, for example from 50% to 70%
by weight, of one or more vinyl aromatic comonomer a), up to 79.9%
preferably 60% or less, for example from 25% to 49% by weight of
one or more 1,3-diene comonomer b) from 0.01 to 15% preferably from
0.5% to 10% or, more preferably from 1% to 5% by weight of
comonomer c), and from 0 to 40%, preferably 0 to 20% or, more
preferably 10% or less, by weight, of comonomer d), based on the
total weight of monomers used to make the copolymer.
[0025] The comonomers and their weight proportions are chosen so as
to make a copolymer having a glass transition temperature (Tg) of
from -60.degree. C. and above, preferably -20.degree. C. or more,
or, more preferably, -10.degree. C. and above, or up to or less
than 80.degree. C., preferably up to or less than 35.degree. C. or,
more preferably up to or less than 25.degree. C. If the Tg is too
high for use in cement compositions, end use properties suffer,
such as flexibility, especially in cold temperatures, and crack
bridging. The Tg of the copolymers can be determined in a known
manner by differential scanning calorimetry (DSC). In uses as a
sacrificial binder in ceramic processing, the useful Tg of the SB
RDP can be as high as 110.degree. C., preferably 60.degree. C.
[0026] Suitable comonomers a) include, for example, styrene,
alpha-methylstyrene, C.sub.1-C.sub.4 alkyl-styrenes, such as
o-vinyltoluene and tert-butylstyrene. Styrene is preferred.
Suitable comonomers b) include, for example, 1,3-butadiene and
isoprene, 1,3-butadiene being preferred. Suitable comonomers c)
include, for example, ethylenically unsaturated mono-carboxylic
acids, and/or di-carboxylic acids, their anhydrides, and their
salts, and mixtures thereof, particularly itaconic acid and/or
maleic acid and/or fumaric acid to improve the dispersibility of
the redispersible copolymer powder.
[0027] Suitable optional comonomers d) include, for example, alkyl
esters of (meth)acrylic acid, such as, for example, methyl
methacrylate, ethylenically unsaturated carboxamides and
carbonitriles, such as, for example, (meth)acrylonitrile; diesters
of fumaric acid or maleic acid; hydroxy alkyl(meth)acrylates;
sulfur acid monomers, phosphorus acid monomers, crosslinking
comonomers, such as, for example, divinyl benzene or divinyl
adipates; postcrosslinking comonomers, such as acrylamidoglycolic
acid (AGA) or allyl methacrylates; epoxy-functional comonomers,
such as glycidyl(meth)acrylates; and silicon-functional comonomers,
such as alkoxysilane containing (meth)acrylates or vinyl
monomers.
[0028] To increase the water redispersibility of the powder
obtained upon drying, a basic compound, as described above, can be
added prior to substantially drying the aqueous copolymer
dispersion.
[0029] In a preferred embodiment, to achieve good water
redispersibility and good odor control, 75% or more, preferably,
85% or more, or, more preferably, 95% or more of the total number
of carboxyl groups in the copolymer are located at the surface of
the copolymer latex particles in the powder particles. In such
copolymers, 75% or more, preferably, 85% or more, or, more
preferably, 90% or more, or, most preferably, 95% or more of the
surface carboxyl groups are present in their salt form in the
copolymer latex particles in the powder.
[0030] A high percentage of the carboxylic groups located at the
surface of the copolymer particles obtained upon drying can be
obtained by the sole use of ethylenically unsaturated dicarboxylic
acid(s) as comonomer c), by staged monomer feeding, such as
addition of the comonomer c) at an advanced stage of the
polymerizations, or by conducting the polymerization at a pH of
from 3 to 9 preferably, from 4 to 8, or, preferably 6 or
higher.
[0031] The percentage of the carboxylic groups that are located at
the surface of the polymer particles in the powder obtained upon
drying encompasses all of the carboxylic groups located at the
surface of the copolymer particles, those located in the liquid
phase in low molecular weight acid aqueous solution copolymers or
as free carboxylic acids or their salts, e.g. citric acid. Upon
drying of the aqueous copolymer dispersion, the carboxylic groups
located in the liquid phase solution copolymers deposit on the
surface of the copolymer particles.
[0032] The sum of the molar amount of carboxylic groups located at
the surface of the copolymer particles and the molar amount of
carboxylic groups in the liquid phase of the aqueous dispersion are
separately measurable in conventional manner.
[0033] In embodiments of the invention, the water insoluble film
forming polymer has an amount of carboxylation as described above
for comonomer c), such as, for example, from 0.1% by weight to 15%
by weight, preferably from 0.5% by weight to 10% by weight, more
preferably from 1% by weight to 5% by weight, of itaconic acid
based upon the total comonomer weight or the weight of the water
insoluble film forming polymer.
[0034] In accordance with the present invention, the water
insoluble film-forming polymer in the aqueous dispersion or latex
which is to be spray dried may have an average particle size of
from 100 nm to 500 nm, for example from 130 nm to 350 nm.
[0035] In embodiments of the invention, the water redispersible
polymer powder compositions of the present invention include a
co-dried admixture of a water insoluble film-forming polymer, a
colloidal stabilizer for colloidal stabilization and
redispersibility of polymer powders into submicron particle sizes,
and a polyglycol. Conventional colloidal stabilizers, such as
polyvinyl alcohol (PVOH) may be employed as a colloidal stabilizer
in conventional amounts. Preferred polyvinyl alcohols for use
herein are partially hydrolyzed polyvinyl alcohols. In embodiments
of the invention, the amount of PVOH or other known colloidal
stabilizers employed to achieve colloidal stability may be at least
1% by weight, for example from 2% by weight to 30% by weight,
preferably from 5% by weight to 20% by weight, based upon the
weight of the water insoluble film-forming polymer. In preferred
embodiments of the invention, the polyglycol may be added after
spray drying. The polyglycol may be combined with a redispersible
polymer powder (RDP) to obtain a redispersible polymer powder
composition of the present invention using conventional mixing or
blending equipment and methods for admixing ingredients to obtain a
dry mix, preblend, or powder composition. In aspects of the present
invention, the redispersible polymer powder composition may be
produced by drying an aqueous mixture of the water insoluble
film-forming polymer and the colloidal stabilizer, with the
polyglycol to obtain a water redispersible polymer powder (RDP), or
by post spraying drying addition of the polyglycol. For example, an
aqueous dispersion of the water insoluble film-forming polymer may
be provided by polymerization, and the colloidal stabilizer may be
admixed with the aqueous dispersion after polymerization, and then
the aqueous dispersion may be spray dried to obtain the water
redispersible polymer powder. The water redispersible polymer
powder (RDP) may then be admixed with a polyglycol, to obtain a
redispersible polymer powder composition of the present invention.
In embodiments of the invention, the polyglycol may be preblended
with a flow agent, carrier or adsorbent such as amorphous silica
powder to obtain a dryblend, and the dryblend may then be admixed
with the redispersible polymer powder (RDP) to obtain a water
redispersible polymer powder composition of the present invention.
The redispersible polymer powder composition may be employed in a
dry mix formulation for cement-based compositions in an amount of
at least 0.1% by weight, for example at least 0.5%, preferably at
least 1% by weight, based upon the weight of the dry mix
formulation.
[0036] In accordance with the method of making the redispersible
polymer powder compositions of the present invention, a water
redispersible polymer powder may be produced by drying an aqueous
mixture of the water insoluble film-forming polymer and a colloidal
stabilizer with or without the polyglycol to obtain a water
redispersible polymer powder. In embodiments, an aqueous dispersion
of the water insoluble film-forming polymer obtained by
polymerization, is admixed with the colloidal stabilizer, with or
without the polyglycol, to obtain a substantially homogeneous
aqueous dispersion which is then spray dried to obtain a water
redispersible polymer powder. In one example, the viscosity of the
feed to be spray-dried may be adjusted via the solids content so
that a value of less than 1000 mPas (Brookfield viscosity at 20
revolutions and 23.degree. C.), preferably less than 250 mPas, is
obtained. The solids content of the dispersion to be spray-dried
may generally be from 25% to 75% by weight, for example from 35% by
weight to 65% by weight, preferably from 40% to 60% by weight,
based on the total weight of the dispersion. To prepare the
water-redispersible polymer powders, the aqueous dispersions are
dried, preferably by spray drying. Spray drying can be carried out
in customary spray drying plants, with atomization being carried
out by means of single-fluid, two-fluid or multifluid nozzles or a
rotary disc atomizer. In general, air, nitrogen or nitrogen
enriched air may be employed as the drying gas, the inlet
temperature of the drying gas generally not exceeding 200.degree.
C., preferably from 110.degree. C. to 180.degree. C., more
preferably from 130.degree. C. to 170.degree. C. The outlet
temperature may generally be from 45.degree. C. to 120.degree. C.,
preferably from 60.degree. C. to 90.degree. C., depending on the
plant, the T.sub.g of the polymeric composition and the desired
degree of drying.
[0037] In addition to the colloidal stabilizer and the polyglycol,
conventional optional additives in conventional amounts can be
added prior to drying the aqueous dispersion, such as an
antifoaming agent in an amount of up to 1.5% by weight of antifoam,
based on the weight of the polymer particles. Other additives which
may be employed, in conventional amounts, include one or more
salts, such as CaCl.sub.2, and MgCl.sub.2, emulsifiers or
surfactants, monosaccharides, disaccharides, and anticaking agents
(antiblocking agents) such as kaolin, calcium carbonates or
silicates. The amount of the anticaking agent, or other inorganic
fillers may be up to 40% by weight, based upon the weight of the
water redispersible polymer powder (RDP). In embodiments of the
invention, conventional superplasticizers may be employed in an
amount of at least 0.01% by weight, preferably from 5% by weight to
25% by weight, based upon the weight of the water redispersible
polymer powder (RDP).
[0038] The X50 size of the particle size distribution of the
redispersible powder depends on drying conditions and drying
equipment. X50 represents the median diameter in micrometers, which
means that 50% by weight of the particles are smaller than this
diameter. The produced water-redispersible polymer powder
preferably has an X50 particle size diameter of from 5 to 100
micrometers, preferably from 20 to 100 micrometers, most preferably
from 50 to 80 micrometers. The particle size distribution of the
powder can be measured by laser diffraction using a particle size
analyzer "Sympatec Helos" at a measuring range of 1.8-350 .mu.m and
dispersing the powder by compressed air.
[0039] The weight of the polymer particles in the powder may
preferably be from 40% by weight to 95% by weight, more preferably
from 65% by weight to 85% by weight, of the total weight of the
water-redispersible polymer powder.
[0040] The polyglycol employed in the present invention may be any
conventional polyglycol, such as a polyethylene glycol, a
polypropylene glycol, or any other polyether diol or triol. In
preferred embodiments, a polypropylene glycol, or polypropylene
oxide, may be employed, with the end group generally being a
hydroxyl group, such as in a polypropylene glycol, diol (PPG). The
amount of polyglycol admixed with the RDP to form the RDP
composition may be from 0.001% by weight to 10% by weight,
preferably from 0.1% by weight to 5% by weight, more preferably
from 0.5% by weight to 3% by weight, based upon the weight of the
water redispersible polymer powder (RDP), or the weight of the
redispersible polymer powder composition. The polyglycol, such as a
polypropylene glycol, may have a number average molecular weight of
from 250 to 10,000, preferably from 1,500 to 6,000. The polyglycol
may be employed in the form of a liquid or a solid, preferably in
the form of a dry preblend or powder with a conventional flow
agent, carrier or adsorbent such as an amorphous silica powder. The
polyglycol in liquid form may be admixed, or preblended, with the
flow agent, carrier, or adsorbent, such as amorphous silica powder
until it is absorbed onto or by it to form a dry preblend or
powder, which in turn may be dryblended or admixed with the RDP to
form a powder or dry mix. In exemplary embodiments of the
invention, the resulting polyglycol powder or dry mix may contain
the flow agent, carrier, or adsorbent in an amount of from 25% by
weight to 60% by weight, for example from 30% by weight to 50% by
weight, based upon the total weight of the polyglycol and the flow
agent, carrier, or adsorbent, such as amorphous silica powder.
[0041] The water-redispersible polymer powder compositions of the
present invention have a variety of uses. In embodiments of the
invention, the carboxylated styrene-butadiene redispersible polymer
powder compositions of the present invention may be employed in
blends with one or more acrylic redispersible polymer powders
(RDPs), VAE RDPs, VAE/VeoVA RDPs, epoxy based RDPs, polyurethane
RDPs, polyolefin dispersion based RDPs, and mixtures thereof. The
powders of the present invention may be employed as functional
additives in a wide variety of compositions such as construction
materials, personal care compositions, pharmaceutical compositions,
and agricultural compositions, in high salt concentration
applications or environments, such as off-shore oil well cementing,
oil and gas drilling and cementing, and in hard water. Additional
uses of the powders are in waste management applications, such as
compositions for synthetic covers for bulk material piles, such as
waste, coal sludge containment, soil, soil erosion control, which
minimize water infiltration, nuisance fugitive dust, odor, and
affinity to birds. The powders may be used in alternative landfill
covers that are sprayable, use inexpensive widely available and
environmentally friendly recycled materials, have good adherence to
plastics and glass waste, and can form/harden within a short time,
and in adhesion enhancing admixtures. The powders may also be
employed in the production of foams, such as polyurethane
foams.
[0042] In preferred embodiments, the water-redispersible polymer
powder may be used as an additive in a setting composition which
may further include an inorganic hydraulic binder. Examples of
inorganic binders include cements, such as Portland cement, alumina
cement, pozzolanic cement, slag cement, magnesia cement and
phosphate cement; gypsum hemihydrate and water-glass. Illustrative
uses of the polymer composition according to the present invention
are in tile adhesives, construction adhesives, renders, joint
mortars, plasters, troweling compositions, filling compositions,
such as floor filling compositions (e.g. self-leveling flooring
compounds), concrete repair joints, joint mortars, tape joint
compounds, concrete, water proofing membrane applications, crack
isolation membrane applications, and additives for ceramic
processing. In particular, the use of the water-redispersible
polymer powder described herein in a setting composition, e.g. in
cement-based tile adhesives or in external thermal insulation
composite systems, result in compositions with high initial
adhesion strength, high adhesion strength after immersion in water
(water resistance), and high adhesion strength after allowing a
certain "open time" before final application of the hydrated
setting composition. In embodiments of the invention, the
water-redispersible polymer powder may be employed as a binder for
slip casting, of for example raw materials such as silica, alumina,
alkali metal oxides, and alkaline earth metal oxides.
[0043] A preferred use of the water-redispersible polymer powder is
in cementitious or hydraulic compositions or other compositions
which exhibit a high pH, for example a pH of at least 11, for
example from 11.5 to 13.5. The redispersible polymer powders of the
present invention may be employed in tile adhesives, such as
cement-based tile adhesives. Cement-based tile adhesives may
generally comprise 5 to 50 parts by weight of cement, preferably
Portland cement, as the hydraulic binder; 40 to 70 parts by weight
of quartz sand, preferably having a particle size of from 0.1 mm to
0.5 mm, as the main filler, and 0.1% to 10% by weight, preferably
1% to 6% by weight (based on the dry weight of the tile adhesive)
of the redispersible polymer powder composition according to the
present invention. Further optional components include one or more
cellulose ethers (preferably in a total amount of 0.05% to 1% by
weight, more preferably 0.2% to 0.5% by weight, based on the dry
weight of the tile adhesive) to control rheology, water retention,
slip resistance and improved workability; quartz or lime stone
powder having a particle size of from 30 .mu.m to 60 .mu.m as fine
co-filler to improve consistency and workability; and cellulose or
mineral fibers to improve the slip resistance.
[0044] Another use of the water-redispersible polymer powders is in
self-leveling flooring compounds SLFC. The powders may be added to
improve the adhesion to the substrate, the flexibility, the
abrasion resistance and the aging properties. The SLFC may
generally include the same components in the same amounts as
employed in the CBTAs. A retarder or retardant, such as trisodium
citrate (TriNa-Citrate), such as Censperse PC13 available from
Newchem AG, Pfaffikon, Switzerland, may be employed in reduced
amounts, such as at least 30% by weight, preferably at least 50% by
weight or more, compared to conventional amounts generally employed
in SLFC. In embodiments of the invention, the retarder may be
employed in an amount of less than or equal to 0.1% by weight, for
example from 0.03% by weight to 0.07% by weight, based on the
weight of the SLFC. The SLFC may also include calcium sulfate
(gypsum), an accelerator, such as lithium carbonate, and a
liquefier, dispersant, or superplasticizer, such as a water soluble
co-polymer dispersant, such as MELFLUX 2651F, modified
polycarboxylates (BASF Construction Polymers, Kennesaw Ga.), in
conventional amounts. In other embodiments, the water-redispersible
polymer powder may be used in external thermal insulation systems
ETICS, particularly as an adhesive on the thermally insulating
board layer to reduce the water absorption and improve the impact
resistance of the external thermal insulation system.
[0045] Furthermore, the water-redispersible polymer powder
according to the present invention may be used in paper products,
paperboard products, carpet backing, paints or coatings or in
binders for wood, paper or textiles coatings or impregnating
compositions, preferably in the absence of a substantial amount of
an inorganic hydraulic binding agent, more preferably in the
absence of any amount of an inorganic hydraulic binding agent. For
example, the water-redispersible polymer powder may be used as the
sole binder in coating compositions and adhesives.
[0046] The following examples are provided for illustrative
purposes only and are not intended to limit the scope of the claims
that follow. Unless otherwise indicated, all parts and percentages
are by weight, all temperatures are in .degree. C., and all
pressures are in bars or atmospheric unless otherwise indicated to
the contrary:
Example 1
[0047] A redispersible polymer powder was produced by admixing: a)
a water insoluble film forming carboxylated styrene butadiene (SB)
latex which has a comonomer content of 62 parts styrene, 35 parts
butadiene, and 3 parts itaconic acid (a carboxylation of 3% by
weight of itaconic acid, based upon the total comonomer weight),
with a particle size of 148 nm, and a T.sub.g of 8.degree. C., and
b) 12% by weight of MOWIOL 4-88, based upon the weight of the latex
polymer. The MOWIOL 4-88 is a partially hydrolyzed PVOH
(polyvinylalcohol) in granular form, and is available from Kuraray
Europe GmbH, Division PVA/PVB D-65926 Frankfurt am Main, Germany.
The MOWIOL 4-88 has a viscosity DIN 53015 of 4.+-.0.5 mPa-s (4%
aqueous solution at 20.degree. C.), a degree of hydrolysis
(saponification) of 87.7.+-.1.0 mol. %, an ester value DIN 53401 of
140.+-.10 mg KOH/g, a residual acetyl content of 10.8.+-.0.8 w/w %,
and a maximum ash content of 0.5% (calculated as Na.sub.2O). The
mixture has a total solids content of 38% by weight, based upon the
total weight of the mixture.
[0048] This mixture may be pumped to a two-fluid nozzle atomizer
equipped on a Mobile Minor spray dryer. The air pressure to the
nozzle may be fixed at 3 bar with 50% flow which is equivalent to 6
kg/hr of airflow. The spray drying may be conducted in an N.sub.2
environment with an inlet temperature fixed at 140.degree. C., and
the outlet temperature targeted to 50.degree. C..+-.1.degree. C. by
tuning the feed rate of the mixture. Concurrently, kaolin powder
(KaMin HG 90) may be added into the chamber for spray drying as an
anti-caking agent, with the amount being controlled to be 12% by
weight of the dry powders.
[0049] The styrene butadiene redispersible polymer powder obtained
by the spray drying ("SB RDP") may have an average particle size
(X50) of 58.4 .mu.m. The spray dried powder is readily dispersed
into deionized (DI) water at a 1% by weight solids level, to the
original SB latex particle size distribution.
[0050] A water redispersible polymer powder composition of the
present invention may be produced by admixing the redispersible
polymer powder SB RDP with a polyglycol. The polyglycol employed
may be VORANOL 2000L which is a polypropylene glycol, diol having
an average molecular weight (M.sub.n, g/mol, as extrapolated from
measured OH in conventional manner) of 2000, an OH number range of
53-58 (mg (KOH)/g phthalic anhydride-pyridine solution), a
viscosity at 25.degree. C. of 320 mPas, a pH of 6.0 to 7.5
(water/isopropanol 6:10 mixture) and a K+Na ppm max of 5 (by flame
photometry). The VORANOL 2000L polyglycol may be first admixed with
a flow agent, carrier, adsorbent, or anti-caking agent, ZEOFREE
5161 which is a spray dried powder form of a precipitated silica
(silicon dioxide; precipitated amorphous silica) having an average
particle size of 20.0 to 35.0 micrometer, and a surface area, BET,
of 160 m.sup.2/g, produced by J. M. Huber Finland OY, to obtain a
powder or dryblend (DB A). The polypropylene dryblend (DB A) may
contain 60% by weight of polypropylene glycol and 40% by weight of
precipitated silica. The polypropylene dryblend may be admixed with
the SB RDP using a conventional mixer to obtain a water
redispersible polymer powder composition of the present invention
having 2% by weight of polypropylene glycol (active substance),
based upon the weight of the SB RDP.
Examples 2-5
[0051] A redispersible polymer powder composition was produced as
in Example 1 except that in Examples 2, 3, 4, and 5, the
polypropylene dryblend (DB A) may be admixed with the SB RDP to
obtain a water redispersible polymer powder composition of the
present invention having 1% by weight, 3% by weight, 5% by weight,
and 6% by weight, respectively, of polypropylene glycol (active
substance), based upon the weight of the SB RDP.
Comparative Example A
[0052] A redispersible polymer powder (SB RDP) as obtained in
Example 1 was used as a comparative example of an RDP which did not
contain any polyglycol (DB A) admixed with it.
Comparative Example B
[0053] A commercially available redispersible polymer powder DLP
2000 which is a Vinylacetate-ethylene copolymer (VAE RDP) having a
T.sub.g of 17.degree. C., an ash content of 10% by weight, and is
colloidally stabilized with PVOH, produced by The Dow Chemical
Company, Midland, Mich. was used as a comparative example of an RDP
which was not a carboxylated SB RDP and which did not contain any
polyglycol (DB A) admixed with it.
Comparative Examples C, D, E, and F
[0054] Comparative redispersible polymer powder compositions C, D,
E, and F were prepared by admixing: a) the Vinylacetate-ethylene
copolymer RDP (VAE RDP) of Comparative Example B, and b) the
polypropylene dryblend (DB A) of Example 1 to obtain water
redispersible polymer powder compositions, Comparatives C, D, E,
and F, having respectively 1%, 3%, 5%, and 6% by weight of
polypropylene glycol (active substance), based upon the weight of
the VAE RDP. Comparative examples C-F are used as comparative
examples of an RDP which is not a carboxylated SB RDP and which
does contain a polyglycol (DB A) admixed with it.
Example 6
[0055] The components and their relative amounts (% by weight or
parts by weight, pbw) which may be used to prepare cement-based
mortar compositions using the redispersible powder compositions of
Examples 1 and 2, and Comparative Examples A and B are shown in
Table 1, below. The different cement-based mortar compositions may
be prepared by dry blending the solid components indicated in Table
1A, and then adding water. Various properties of the cement-based
mortar compositions and their performance may be tested and the
results are shown in Table 1B.
Test Methods
[0056] Dry Mix Preparation: The cement, sand, polymer, and
thickener are weighed and placed into a plastic bag which is then
hand mixed for 2 minutes and conditioned for 24 hrs.
[0057] CE 5.12 (Wet mortar Brookfield viscosity, wettability and
density). Viscosities are measured with a Brookfield
Synchro-lectric viscometer (Model RVT) in combination with a
Brookfield Helipath stand at 25.degree. C. The mortar is filled
into a density cup and the spindle (T-F) is positioned such that it
just touches the surface of the mortar.
[0058] Density: Mortars are placed into a container of known
volume, tamped down, and then weighed.
[0059] Wettability: Amount of mortar transfer to the back of the
tile
[0060] Open time: EN 1346 20 minutes, after 7 days and after 28
days.
[0061] Adhesion: EN 1348 after 28 days at room temperature, and
70.degree. C., and water immersion.
TABLE-US-00001 TABLE 1A Cement-based Mortar Formulations Formula
(parts by Weight) Ex. 1 Ex. 2 Comp. A Comp. B RAW MATERIAL SB SB SB
VAE Portland Cement, Jura PZ 42.5 40.00 40.00 40.00 40.00 Sand
Zimmerli, Silica Sand 0.1-0.45 mm 60.00 60.00 60.00 60.00
Polypropylene glycol 0.06 0.03 -- -- Redispersible Polymer Powder
of Example 1 3.00 -- -- -- Redispersible Polymer Powder of Example
2 -- 3.00 -- -- Redispersible Polymer Powder of -- -- 3.00 --
Comparative Example A Redispersible Polymer Powder of -- -- -- 3.00
Comparative Example B Methocel MC 10-0148, (hydroxypropyl 0.40 0.40
0.40 0.40 methyl cellulose (HPMC) modified with starch ether,
thickener (Dow Chemical Co.) Total, % by weight 103.46 103.43
103.40 103.40 Water 22.0 22.0 22.0 23.0
TABLE-US-00002 TABLE 1B Adhesion Results TEST RESULTS Initial
Strength 28 days N/mm.sup.2 2.83 1.73 1.89 1.67 20 minute Open Time
28 days N/mm.sup.2 1.13 1.09 0.88 1.00 Water Immersion 28 days
N/mm.sup.2 2.07 1.44 1.30 1.17 Heat aging 28 days 70.degree. C.
N/mm.sup.2 2.58 2.27 1.98 1.89 Wettability % 95 100 100 80 Density
kg/1 1.66 1.49 1.43 1.51 Consistency 0.5 rpm cps*1000 2596 2836
2611 2765 Consistency 5 rpm cps*1000 583 469 506 425 Consistency 50
rpm cps*1000 86 94 86 88
[0062] As shown in Table 1B, an unexpectedly superior improvement
in adhesion values when styrene-butadiene carboxylated polymer
powder is modified with 0.03% by weight of polyglycol (Example 2,
1% by weight polyglycol, based upon the weight of the RDP) and
0.06% by weight polyglycol (Example 1, 2% by weight polyglycol,
based upon the weight of the RDP) and used as a redispersible
polymer powder composition instead of the same powder non modified
(Comparative Example A), or a VAE RDP which is non-modified
(Comparative Example B).
[0063] In addition, eight mortar formulas for the consistency
measurements were obtained by admixing 127.2 g cement, 50.4 g water
and 7.2 g of the RDP compositions of Examples 2, 3, and 4, and
Comparative Examples A, B, C, D, and E, according to the
recipe:
Recipe: 127.2 g cement+7.2 g (powder+active substance of DB A)+50.4
g water, where DB A=4 pts. Zeofree 5161A+6 pts. Voranol 2000L
(polyglycol); Voranol 2000L=active substance. For example, 7.2 g
powder (100%) (0% active substance) 7.13 g powder (99%)+0.12 g DB A
(1% active substance) 6.99 g powder (97%)+0.35 g DB A (3% active
substance) 6.86 g powder (95%)+0.57 g DBA (5% active substance)
[0064] The consistency of cement/VAE and SB powder with DB A/water
mixtures is shown in the sole FIGURE as a function of the amount of
polyglycol added, DB A [% active substance]. The consistencies are
measured with a rotating T-Spindel. As shown in the sole FIGURE, a
mortar formulated with a carboxylated styrene butadiene RDP and
polyglycol as in Examples 2, 3, and 4 exhibits an unexpectedly high
increase in consistency compared to the consistency of SB RDP and
VAE RDP which do not contain a polyglycol as in Comparative
Examples A and B, respectively, and VAE RDPs which do include a
polyglycol as in Comparative Examples C, D, and E. The sole FIGURE
shows the different behavior of polyglycol in VAE- and SB
redispersible polymer powder/cement mixtures. The increase of the
consistency with the SB powder has no negative impact on the
application properties. The higher consistency in the case of SB
powder indicates that there is a surprising interaction between SB
and cement
Example 7
[0065] The components and their relative amounts (% by weight or
parts by weight, pbw) which may be used to prepare cement-based
mortar compositions using the redispersible powder compositions of
Example 5, and Comparative Example F are shown in Table 2, below.
The different cement-based mortar compositions may be prepared by
dry blending the solid components indicated in Table 2, and then
adding water. Various properties of the cement-based mortar
compositions and their performance may be tested and the results
are shown in Table 2.
Test Methods
[0066] Flow and spreading: The flow is determined by measuring the
diameter of the spread material in two directions perpendicular to
each other. The required diameter depends on the size of the tube
used. The tube described in the draft version of the EN has a
diameter of 30 mm and a height of 50 mm. For this tube the required
diameter for a SLFC should be >150 mm
[0067] Merge properties: The merge properties are determined in
many different manners. There are no defined requirements.
[0068] Viscosity: There is no defined requirement for the
viscosity. An optimum viscosity, determined via a modified DIN 53
211 (6.5 mm nozzle), has a pour time ranging from 25 to 60 DIN
Seconds. Above 60 DIN seconds there is the risk of entrapping too
much air which cannot escape anymore. Below 25 DIN seconds the
mixture tends to splash and initially formed lumps will not be
re-dissolved anymore because of the missing shear forces.
[0069] Separation: The phase separation can only be subjectively
determined. The mixture should not separate during the open time.
The cohesive strength at different heights of the SLFC layer should
therefore be equal.
[0070] Surface appearance: The determination of the surface
appearance is done visually. No staining, bleeding and pinholes
should be present. It is evaluated subjectively and rated on a
scale from 1 (very poor) to 5 (very good).
[0071] Curing properties (green strength): The strength of the
SLFC, which allows walking on it, is the criteria for the green
strength. Fast setting SLFCs have to reach these properties after 3
to 4 hours. The curing is determined via the determination of the
flexural- and the compressive strength according to EN 196. A
compressive strength of 3-4 MPa is considered as sufficient.
[0072] Flexural and compressive strength: The flexural and the
compressive strength are determined according to EN 196 after 1 d,
7 d and 28 days. The purpose of the 1 d test is described above.
For the 7 d and the 28 d results there are no values specified in
norms. Generally 20 MPa after 28 d is considered as sufficient. The
leading materials in the market have a flexural strength of about 7
MPa (28 d) and a compressive strength of about 30 MPa (28 d).
[0073] Abrasion resistance: Requirements for the abrasion
resistance, determined according to the castor chair test CEN 303,
is dependent on application area (e.g. domestic, industrial
floors).
TABLE-US-00003 TABLE 2 Cement-based Mortar Formulations and Surface
Appearance, Abrasion Resistance, Compressive Strength and Flexural
Strength Results Formula (parts by Weight) Comp 7-A Ex. 7-1 Ex 7-2
Ex 7-3 RAW MATERIAL VAE SB SB SB Portland Cement, Jura PZ 42.5
32.00 32.00 32.00 32.00 Sand, Quarzsand, Silica Sand 0.1-0.45 mm
42.32 42.42 42.37 42.32 Limestone powder 65 micron 12.00 12.00
12.00 12.00 Cement, LaFarge Fondu 6.00 6.00 6.00 6.00 Calcium
Sulfate (Gypsum) 4.00 4.00 4.00 4.00 Trisodium citrate retarder,
Censperse PC 13 0.10 -- 0.05 0.10 Lithium carbonate, accelerator
0.10 0.10 0.10 0.10 Melflux 2651 F liquefier 0.40 0.40 0.40 0.40
Polypropylene glycol, 6% by weight of RDP Yes Yes Yes Yes
Redispersible Polymer Powder Composition of 3.00 -- -- --
Comparative Example F (VAE RDP and 10% DB A) Redispersible Polymer
Powder Composition of -- 3.00 3.00 3.00-- Example 5 (SB RDP and 10%
DB A) Methocel CP 1119, (hydroxypropyl methyl cellulose 0.40 0.40
0.40 0.40 ether (HPMC)) thickener (Dow Chemical Co.) Total, % by
weight 100.00 100.00 100.00 100.00 Water 27.00 27.00 27.00 27.00
TEST RESULTS, Properties Flow Properties 1 minute 1 min. 1 min. 1
min. a) Flow diameter 1'', mm 151 156 142 142 b) Flow diameter
15'', mm 150 142 143 147 c) Flow merge property, mm 98 89 95 90 d)
DIN cup 1'', sec 40 42 46 58 e) DIN cup 15'', sec 67 80 71 70 Final
Surface Characteristics a) Phase Separation <5 5 5 5 b)
Coloration 4 >4 <5 <5 c) Pin Holes 4 5 5 5 Compressive
Strength N/mm.sup.2 after 3 days 3.19 3.99 4.50 4.02 Compressive
Strength N/mm.sup.2 after 7 days 3.23 3.96 6.37 5.20 Compressive
Strength N/mm.sup.2 after 28 days 7.83 6.91 9.89 8.56 Flexural
Strength N/mm.sup.2 after 3 days 14.03 12.08 17.00 17.69 Flexural
Strength N/mm.sup.2 after 7 days 20.15 22.45 26.85 23.60 Flexural
Strength N/mm.sup.2 after 28 days 30.30 26.10 33.80 33.15
Production Floor Test--Platten Results (grams) 30.2 2.9 3.8 16.2
10000X 9283X 10000X 10000X
[0074] As shown in Table 2, surface appearance (coloration and pin
holes) is improved and unexpected improvement (10.times.) in
abrasion resistance value is obtained when styrene-butadiene
carboxylated polymer with polyglycol is used as a redispersible
polymer powder composition instead of Ethylene Vinyl Acetate with
polyglycol. Also, unexpectedly superior compressive strength and
flexural strength values are obtained when the formulation contains
50% less of retardant (TrNaCitrate) compared to standard amounts,
which also results in an important cost reduction.
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